【正文】 rain the operators to better maintain their equipment. Policy : 1. Achieve and sustain availability of machines 2. Optimum maintenance cost. 3. Reduces spares inventory. 4. Improve reliability and maintainability of machines. Target : 1. Zero equipment failure and break down. 2. Improve reliability and maintainability by 50 % 3. Reduce maintenance cost by 20 % 4. Ensure availability of spares all the time. Six steps in Planned maintenance : 1. Equipment evaluation and recoding present status. 2. Restore deterioration and improve weakness. 3. Building up information management system. 4. Prepare time based information system, select equipment, parts and members and map out plan. 5. Prepare predictive maintenance system by introducing equipment diagnostic techniques and 6. Evaluation of planned maintenance. PILLAR 5 QUALITY MAINTENANCE : It is aimed towards customer delight through highest quality through defect free manufacturing. Focus is on eliminating nonconformances in a systematic manner, much like Focused Improvement. We gain understanding of what parts of the equipment affect product quality and begin to eliminate current quality concerns, then move to potential quality concerns. Transition is from reactive to proactive (Quality Control to Quality Assurance). QM activities is to set equipment conditions that preclude quality defects, based on the basic concept of maintaining perfect equipment to maintain perfect quality of products. The condition are checked and measure in time series to very that measure values are within standard values to prevent defects. The transition of measured values is watched to predict possibilities of defects occurring and to take counter measures before hand. Policy : 1. Defect free conditions and control of equipments. 2. QM activities to support quality assurance. 3. Focus of prevention of defects at source 4. Focus on pokayoke. ( fool proof system ) 5. Inline detection and segregation of defects. 6. Effective implementation of operator quality assurance. Target : 1. Achieve and sustain customer plaints at zero 2. Reduce inprocess defects by 50 % 3. Reduce cost of quality by 50 %. Data requirements : Quality defects are classified as customer end defects and in house defects. For customerend data, we have to get data on 1. Customer end line rejection 2. Field plaints. Inhouse, data include data related to products and data related to process Data related to product : 1. Product wise defects 2. Severity of the defect and its contribution major/minor 3. Location of the defect with reference to the layout 4. Magnitude and frequency of its occurrence at each stage of measurement 5. Occurrence trend in beginning and the end of each production/process/changes. (Like pattern change, ladle/furnace lining etc.) 6. Occurrence trend with respect to restoration of breakdown/modifications/periodical replacement of quality ponents. Data related to processes: 1. The operating condition for individual subprocess related to men, method, material and machine. 2. The standard settings/conditions of the subprocess 3. The actual record of the settings/conditions during the defect occurrence. PILLAR 6 TRAINING : It is aimed to have multiskilled revitalized employees whose morale is high and who has eager to e to work and perform all required functions effectively and independently. Education is given to operators to upgrade their skill. It is not sufficient know only KnowHow by they should also learn Knowwhy. By experience they gain, KnowHow to overe a problem what to be done. This they do without knowing the root cause of the problem and why they are doing so. Hence it bee necessary to train them on knowing Knowwhy. The employees should be trained to achieve the four phases of skill. The goal is to create a factory full of experts. The different phase of skills are Phase 1 : Do not know. Phase 2 : Know the theory but cannot do. Phase 3 : Can do but cannot teach Phase 4 : Can do and also teach. Policy : 1. Focus on improvement of knowledge, skills and techniques. 2. Creating a training environment for self learning based on felt needs. 3. Training curriculum / tools /assessment etc conductive to employee revitalization 4. Training to remove employee fatigue and make work enjoyable. Target : 1. Achieve and sustain downtime due to want men at zero on critical machines. 2. Achieve and sustain zero losses due to lack of knowledge / skills / techniques 3. Aim for 100 % participation in suggestion scheme. Steps in Educating and training activities : 1. Setting policies and priorities and checking present status of education and training. 2. Establish of training system for operation and maintenance skill up gradation. 3. Training the employees for upgrading the operation and maintenance skills. 4. Preparation of training calendar. 5. Kickoff of the system for training. 6. Evaluation of activities and study of future approach. PILLAR 7 OFFICE TPM : Office TPM should be started after activating four other pillars of TPM (JH, KK, QM, PM). Office TPM must be followed to improve productivity, efficiency in the administrative functions and identify and eliminate losses. This includes analyzing processes and procedures towards increased office automation. Office TPM addresses twelve major losses. They are 1. Processing loss 2. Cost loss including in areas such as procurement, accounts, marketing, sales leading to high inventories 3. Communication loss 4. Idle loss 5. Setup loss 6. Accuracy loss 7. Office equipment breakdown 8. Communication channel breakdown, telephone and fax lines 9. Time spent on retrieval of information 10. Non availability of correct on line stock status 11. Custom